Load absorbing direct metal deposition raceway bearing with rolling contact

ABSTRACT

A bearing constructed in accordance to one example of the present disclosure includes at least one inner bearing ring, at least one outer bearing ring, at least one rolling element and a direct metal deposition (DMD) raceway architecture. The DMD raceway architecture is disposed between the at least one inner and outer bearing rings. The DMD raceway architecture includes an inner DMD structure that defines an inner raceway and an outer DMD structure that defines an outer raceway. The inner and outer raceways are configured to support the at least one rolling element.

FIELD

The present disclosure relates generally to wire race bearings and morespecifically to a wire race bearing having raceways formed by DirectMetal Deposition (DMD).

BACKGROUND

A wire race bearing is a rolling element bearing having rollers that runon races resembling loop sections of wire. Wire race bearings arepreferred in applications subject to shock loads, deflections (out-offlatness conditions) and vibrations. Wire race bearings act as a dampingelement and operate at reduced noise levels compared to some of theother bearings with rolling contact. A known disadvantage to such aconfiguration having a wire is that a gap exists between the start andend of each wire. These gaps are often subject to additional wear, tearand noise generation such as clicking and knocking noises.

The background description provided herein is for the purpose ofgenerally presenting the context of the disclosure. Work of thepresently named inventors, to the extent it is described in thisbackground section, as well as aspects of the description that may nototherwise qualify as prior art at the time of filing, are neitherexpressly nor impliedly admitted as prior art against the presentdisclosure.

SUMMARY

A bearing constructed in accordance to one example of the presentdisclosure includes at least one inner bearing ring, at least one outerbearing ring, at least one rolling element and a direct metal deposition(DMD) raceway architecture. The DMD raceway architecture is disposedbetween the at least one inner and outer bearing rings. The DMD racewayarchitecture includes an inner DMD structure that defines an innerraceway and an outer DMD structure that defines an outer raceway. Theinner and outer raceways are configured to support the at least onerolling element.

According to additional features, one of the inner and outer DMDstructures is formed in two parts. The DMD raceway architecture isformed in multiple layers as one homogeneous cross-section. The DMDraceway architecture is fused to the inner and outer bearing rings. TheDMD raceway architecture is defined by a plurality of solid portions andair pockets providing one of a honeycomb and micro channel-likestructure. The inner and outer raceways are machined to generate afinished raceway surface.

In other features the inner DMD structure comprises a first racestructure having a first inner raceway and a second race structurehaving a second inner raceway. The outer DMD structure comprises a firstsupport structure having a first outer raceway and a second supportstructure having a second outer raceway. The at least one rollingelement includes two rolling elements. A first rolling element isdisposed between the first inner and outer raceway. The second rollingelement is disposed between the second inner and outer raceway. Theinner and outer bearing rings can be formed from one of forged seamlessrolled rings, profiled bar material processed on a bending machine andbutt-welded into a ring, casted rings and flat plate burn-out rings.

A method of making a bearing according to one example of the presentdisclosure includes providing an inner and an outer bearing ring. Araceway architecture is formed by direct metal deposition (DMD) betweenthe inner and outer bearing ring. The raceway architecture defines aninner and outer raceway. At least one rolling element is positionedbetween the inner and outer raceways.

According to other features, an inner DMD structure is formed thatdefines the inner raceway. An outer DMD structure is formed that definesthe outer raceway. The raceway architecture is formed in multiple layersas one homogeneous cross-section. The inner DMD structure is fused tothe inner bearing ring. The outer DMD structure is fused to the outerbearing ring. A plurality of solid portions and air pockets are formedin the raceway architecture providing one of a honeycomb andmicro-channel-like structure. The inner and outer raceways are machined.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a sectional view of a wire race bearing constructed inaccordance to one example of Prior Art;

FIG. 2 is a perspective view of a wire of the wire race bearing of FIG.1 according to Prior Art;

FIG. 3 is a sectional view of a wire race bearing constructed in part byDirect Metal Deposition (DMD) according to one example of the presentdisclosure; and

FIG. 4 is a perspective view of a wire of the wire race bearing of FIG.3 according to one example of the present disclosure.

DETAILED DESCRIPTION

With initial reference to FIG. 1, a wire race bearing constructed inaccordance to one example of Prior Art is shown and generally identifiedat reference 10. The wire race bearing 10 includes an inner bearing ring20, an outer bearing ring assembly 22, first and second rolling elements30, 32, and race wires 40, 42, 44 and 48. The outer bearing ringassembly 22 includes a first outer bearing ring 22A and a second outerbearing ring 22B. A first resilient intermediate ring 50 is disposedbetween the first outer bearing ring 22A and the first rolling element30. A second resilient intermediate ring 52 is disposed between thesecond outer bearing ring 22B and the second rolling element 32. Thewires 40, 42, 44 and 48 have respective raceways 60, 62, 64 and 68 forthe rolling elements 30, 32 to roll along. As shown in FIG. 2, the wire40 includes a gap 70 defined between a beginning point 72 and an endpoint 74 of the wire 40. It is appreciated that the other wires 42, 44and 48 also define respective gaps as well. The main function of thewires 40, 42, 44 and 48 is to provide the respective raceways 60, 62, 64and 68 that address the wear and fatigue of the rolling contact areabetween the rolling elements 30, 32 and the wires 40, 42, 44 and 48. Thewires 40, 42, 44 and 48 have very specific material properties and havehigher hardness that the surrounding material. The wires can betypically sitting in a wire bed that is machined into a companion ring.The companion rings are either seamless rolled rings or profiled barmaterial processed on a bending machine and butt-welded into a ring orcasted rings of any shape and size. The wire race bearing 10 enables anindividual design of the enclosing construction as well as a free choiceof material such as, but not limited to, aluminum.

Turning now to FIGS. 3 and 4, a bearing constructed in accordance toadditional features of the present disclosure is shown and generallyidentified at reference 110. The bearing 110 includes an inner bearingring 120, an outer bearing ring 122, first and second rolling elements130, 132 and a Direct Metal Deposition (DMD) raceway architecture 136.The DMD raceway architecture 136 replaces the wires 40, 42, 44 and 48provided in wire race bearing 10. The DMD raceway architecture 136generally includes an inner DMD structure, collectively identified at140 and an outer DMD structure, collectively identified at 144. Theinner DMD structure 140 can include a first race structure 150 having afirst inner raceway 152 and a second race structure 154 having a secondinner raceway 156. The first and second raceways 152 and 156 arecollectively referred to herein as an inner raceway. The outer DMDstructure 144 can be formed in two parts and include a first supportstructure 160 having a first outer raceway 162 and a second supportstructure 164 having a second outer raceway 166. The first and secondraceways 162 and 166 are collectively referred to herein as an outerraceway. The first raceways 152, 162 and second raceways 156, 166 caneach have an overlap zone resulting in a continuous structure as theyare formed by DMD thus eliminating the undesirable gap 70 (FIG. 2) inprior art examples.

The inner and outer bearing rings 120 and 122 can be formed in oneexample by forged seamless rolled rings. In other examples the inner andouter bearing rings 120 and 122 can be formed by a profiled bar materialprocessed on a bending machine and butt-welded into a ring. In otherarrangements, the inner and outer bearing rings 120 and 122 can becasted rings or flat plate burn-out rings. Other arrangements arecontemplated for the inner and outer bearing rings within the scope ofthe present disclosure.

The first and second support structures 160 and 164 can comprise ahoneycomb or micro channel-like structure. The first and second supportstructures 160 and 164 have a plurality of solid portions 170 and aplurality of air pockets 172. The air pockets 172 inside the DMD racewayarchitecture 136 can act as sound barriers and improve the acousticperformance of the bearing 110.

DMD is a form of rapid tooling process that makes components and moldsfrom metal powder that is melted by a laser and subsequently solidifiedin place. DMD allows the production or reconfiguration of any type ofraceway architecture that is made out of the actual end material, suchas, but not limited to, titanium, tungsten alloys or stellites. The DMDraceway architecture 136 is created by computer aided design and can becustomized for any application. The DMD raceway architecture 136 is madewith multiple layers as one homogeneous cross-section. The DMD racewayarchitecture 136 is fused to the respective inner and outer bearingrings 120 and 122. The tribological raceway system is highlycustomizable from a material property perspective. In this way, theparticular configuration shown in FIGS. 3 and 4 is merely exemplary. Assuch, other geometries having various solid portions and/or air pocketscan be constructed within the scope of the present disclosure.Subsequent to formation of the DMD raceway architecture 136, therespective raceways 162 and 166 are machined by means of hard turning orgrinding to generate a finished raceway surface.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. In this regard, the orderingof method steps is not necessarily fixed, but may be capable of beingmodified without departing from the instant teachings. Such variationsare not to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A bearing comprising: at least one inner bearingring; at least one outer bearing ring; at least one rolling element; anda direct metal deposition (DMD) raceway architecture disposed betweenthe inner and outer bearing ring, the DMD raceway architecture includingan inner DMD structure that defines an inner raceway and an outer DMDstructure that defines an outer raceway, wherein the inner and outerraceways are configured to support the at least one rolling element. 2.The bearing of claim 1 wherein one of the inner and outer DMD structuresis formed in two parts.
 3. The bearing of claim 1 wherein the DMDraceway architecture is formed in multiple layers as one homogeneouscross-section.
 4. The bearing of claim 1 wherein the DMD racewayarchitecture is fused to the inner and outer bearing rings.
 5. Thebearing of claim 1 wherein the DMD raceway architecture is defined by aplurality of solid portions and air pockets providing one of a honeycomband micro channel-like structure.
 6. The bearing of claim 1 wherein theinner and outer raceways are machined to generate a finished racewaysurface.
 7. The bearing of claim 1 wherein the inner DMD structurecomprises a first race structure having a first inner raceway and asecond race structure having a second inner raceway.
 8. The bearing ofclaim 7 wherein the outer DMD structure comprises a first supportstructure having a first outer raceway and a second support structurehaving a second outer raceway.
 9. The bearing of claim 8 wherein the atleast one rolling element comprises two rolling elements, wherein afirst rolling element is disposed between the first inner and outerraceway and the second rolling element is disposed between the secondinner and outer raceway.
 10. The bearing of claim 1 wherein the innerand outer bearing rings are formed from one of forged seamless rolledrings, profiled bar material processed on a bending machine andbutt-welded into a ring, casted rings and flat plate burn-out rings. 11.The bearing of claim 1 wherein the inner raceway and the outer racewayare both continuous.
 12. A method of making a bearing, the methodcomprising: providing an inner bearing ring; providing an outer bearingring; forming a raceway architecture by direct metal deposition (DMD)between the inner and outer bearing ring, the raceway architecturedefining an inner and outer raceway; and positioning at least onerolling element between the inner and outer raceways.
 13. The method ofmaking the bearing of claim 12 wherein forming the raceway architecturefurther comprises: forming an inner DMD structure that defines the innerraceway; and forming an outer DMD structure that defines the outerraceway.
 14. The method of claim 13 wherein forming the racewayarchitecture comprises forming the raceway architecture in multiplelayers as one homogeneous cross-section.
 15. The method of claim 13wherein forming the raceway architecture comprises: fusing the inner DMDstructure to the inner bearing ring; and fusing the outer DMD structureto the outer bearing ring.
 16. The method of claim 12 wherein formingthe raceway architecture comprises forming a plurality of solid portionsand air pockets providing one of a honeycomb and micro-channel-likestructure.
 17. The method of claim 12, further comprising: machining theinner and outer raceways.